Dyeable rubber coated fabrics



June 23, 1964 .1. w. swlGGETT DYEABLE RUBBER COATED FABRICS Filed April 2l, 1960 JACK w. 5w/66577 United States Patent O 3,138,431 DYEABLE RUBBER COATED FABRICS Jack W. Swiggett, Gastonia, N.C., assigner to United States Rubber Company, New York, NX., a corporation of New .lersey Filed Apr. 21, 1960, Ser. No. 23,645 8 Claims. (Cl. 8-11S.5)

This invention relates to latex coating materials which are applied to the back of fabrics. More particularly, the invention relates to fabrics, the back surfaces of which have been treated with a latex coating which is so modied as to be capable of being colored by dyestuifs used to color the fabric yarns.

The application of a latex coating to the back of a fabric, particularly carpeting and upholstery fabrics, is a practical means of stifening up the fabric, locking pile tufts in position, waterproofing, and providing an antislip surface to essentially textile materials. After treatment with latex and vulcanization thereof, the coated fabric may then be colored with various dyestuffs to provide it with a decorative and attractive appearance. However, conventional latex coatings will not accept dyestufs, and consequently retain an unattractive drab yellow or white appearance in contrast with the various colors accepted by the fabric yarns. In addition, should the fabric be one which is loosely woven, the uncolored latex coating will be discernible from the upper surface of the fabric in the interstices formed by the loosely woven individual bers. There is the further disadvantage that'the latex may seep through the loosely woven fibers and/or interstices and overrun portions of the face of the fabric, thereby resulting in areas of uncolored latex not in harmony with the dyed surface of the fabric. These discrepancies in color detract from the appearance of the fabric.

To overcome these disadvantages to the appearance of the finished article, it was heretofore necessary to incorporate into the latex coating material a dyestuif or pigment which most nearly matched the color of the dyestuff to be used on the yarns of the fabric. However, such an operation requires that one know beforehand the color that is to be applied to the fabric, and this is not usually feasible. In addition, a latex formulation must be compounded for every different color that is desired in the fabric which presents distinct problems due to the solubility, color-fastness and similar characteristics peculiar to each particular dyestuff or pigment.

I have now found that conventional latex coating materials may be modied to accept dyestuffs and thereafter be colored substantially the same shade as the fabric to which they are applied as a coating, when said fabric and coating are subjected to a subsequent dyeing treatment.

It is therefore an object of this invention to provide a decoratively dyed fabric having a latex coating on its back surface colored substantially the same shade as the fabric yarns.

Another object is to provide a latex composition suitable for coating fabrics which will accept the same dyestuff as the fabric yarns.

ice

Other and related objects will become apparent as the description of the invention proceeds.

In accordance with the invention, a conventional latex may be modified to accept dyestuffs by incorporating dye acceptors into the latex which result in the modification of the latex so that it will accept direct, acetate, acid and nylon dyes. I have found that a dyeable latex may be produced by incorporating a member selected from the class consisting of polyvinyl pyrrolidone, polyvinyl acetate, acrylic polymers, and combinations thereof into a conventional latex. The polyvinyl pyrrolidone is an acceptor of direct dyes. The polyvinyl acetate and acrylic polymers accept acetate, acid and nylon dyes. The term conventional latex, as used herein, refers to natural and `synthetic rubber latices which have been compounded with the usual ingredients necessary for vulcanization, protection against aging, and with auxiliary chemicals to control wetting and penetration of fabric. The term acrylic polymers, as used herein, refers to polymeric acrylate and methacrylate esters.

The figure is a schematic flow-sheet illustrating the process by which dyeahle rubber-coated fabric can Vbe prepared in accordance with this invention.

For the purposes of this invention, I have found that a suitable range for incorporating polyvinyl pyrrolidone into a latex is from about 1 to about 6 parts by weight, and preferably from about 1 to about 3 parts by weight, based on 100 parts of dry weight compounded latex solids. When incorporating polyvinyl acetate or acrylic polymer into latex, the parts by weight may range from about 10 to about 50 parts of polyvinyl acetate or acrylic polymer, the dry weight compounded latex solids correspondingly ranging from about 90 to about 50 parts by weight. The preferred range for incorporating polyvinyl acetate or acrylic polymer into a latex is from about 20 to about 40 parts by weight with a corresponding 8O to parts by weight of compounded latex solids. Commercially available aqueous solutions and dispersions of polyvinyl pyrrolidone, polyvinyl acetate and acrylic polymers may be used in accordance with this invention. Specific examples of particular compositions falling within the scope of my invention are listed below.

Typical fabrics which may be treated with a latex Coating in accordance with the invention are woven and tufted pile fabrics and similar fabrics in which such coating is used to bind certain yarns, that is, those yarns generally having long reaches at one side of the fabric between tiedown points where they are interlocked with the other yarns in the fabric. Loop or cut pile fabrics and fabrics with long surface floats are examples of fabrics with yarns having long reaches between tie-down points.

As an example, the modified latex coating material of this invention can be applied to upholstery fabrics which may be loosely woven, or where there is a possibility of the latex seeping through the fibers and/ or interstices to the face of the fabric. Most upholstery fabrics are composed of cotton ground and either acetate or nylon pile. These fabrics are dyed with direct dyes on the cotton ground and acetate or nylon dyes on the pile. In such a EXAMPLE l Parts by Chemical Classification Commercial Product Vendor Weight (dry) compounded natural rubber latex LOtol GX-3180 Naugatuek Chemical L-.- 100 Polyvinyl pyrrolidone Peregal ST 1 Antara Chemicals 5 EXAMPLE 2 Compounded natural rubber latex Lotol GX-3l80 Naugatuck Chemical 90 Polyvlnyl acetate Celanese CL-202 3 Celanese Corp 10 EXAMPLE 3 Compounded SBR latex 4 Lotol (iX-1314 Naugatuck Chemical- 80 Polyvinyl acetate Flexbond 400 3--. Colton Chemical Co 20 Polyvinyl pyrrolidone Percgal ST Antara Chemicals 1 EXAMPLE 4 Compoundcd SBR latex Lotol GX-1314 Naugatuek Chemical Polyvinyl acetate Celanese CL-202- Celanese Corp 50 Polyvinyl pyrrolidone Peregal ST Antara Chemicals 3 EXAMPLE 5 Compounded neoprene latex Lotol GX-l076 Naugatuck Chemical 100 Polyvinyl pyrrolidone Peregal ST Antara Chemicals 5 EXAMPLE G Compounded SBR latex Lotol (iX-1314 Naugatuck Chemical 80 Acrylic polymer Rhoplcx B-l5 5. Rohm & Haas Co 20 Polyvinyl pyrrolidone Percgal ST Antara Chemicals l EXAMPLE 7 compounded natural rubber latex Lotol GX-3180 Naugatuck Chemical 70 Acrylic polymer Rhoplex B-l Rohm & Haas Co 30 1 Approximately 30% solids.

2 Naugatuck Chemical Division, U.S. Rubber Co.

8 Approximately 50-55% solids.

4 Compounded latex of styrene-butadiene copolymer rubber. 5 Approximately 46% solids.

case, a latex coating, modified with both polyvinyl pyrrolidone and polyvinyl acetate or both polyvinyl pyrrolidone and acrylic polymer as in Example 3, 4 and 6 above, would be dyed by the same dyestuffs as used on the fabric, thereby improving the appearance of the upholstery material.

Another use of the coating material of this invention is on cotton, nylon or acetate scatter rugs Where it is desirable to have the latex coating on the back of the rug substantially the same color as the rug face. For example, a scatter rug composed of cotton ground and cotton pile would best be coated with a latex modified according to this invention with polyvinyl pyrrolidone as in Example 1. The cotton rug, coated with latex, could then be piecedyed with a direct dye in a wet processing operation, for example, by immersion in a direct dye bath. The latex coating is colored approximately the same shade as the cotton yarn, thereby presenting a uniformly colored article.

Similar results are obtained with materials composed of acetate or nylon fibers or both. Since these materials are dyed by acetate, nylon or acid dyes, they would best be coated with a latex modified according to this invention with polyvinyl acetate as in Example 2 or acrylic polymer as in Example 7.

It is therefore seen that, for dyeing purposes, cotton fabrics are best coated with a latex modified with polyvinyl pyrrolidone. Acetate and/ or nylon fabrics are best coated with a latex modified with polyvinyl acetate or acrylic polymer. Fabrics composed of cotton and acetate or nylon fibers are best coated with a latex modified with both polyvinyl pyrrolidone and polyvinyl acetate or polyvinyl pyrrolidone and acrylic polymer.

Typical of the dyestuffs generally used to color textile materials and which can be used in accordance with this invention, though not limiting the invention thereto, are the following:

The latex coating material of this invention may be applied to fabrics by means of Wet rollers, spraying, or any known manner for applying coatings to fabrics. For example, the latex coating may be applied to one side of a fabric as it passes over a roller the surface of which dips into a latex bath upon rotation. After this application of latex to the back of a fabric, the coated fabric may be passed into a drying and curing oven for the purposes of evaporating the water from the latex, coagulating the rubber and curing the rubber by hot vulcanization.

It is to be understood that the above described embodiments are merely illustrative of my invention. Numerous variations and modifications may be devised by those skilled in the art without departing from the spirit and scope of the invention which is to be determined by the appended claims.

Having thus described my invention, what I claim and desire to protect by Letters Patent is:

1. A rubber-backed fabric consisting of a fabric layer and a rubber coating on the back surface of said fabric layer, said rubber coating comprising :a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber, said latex containing at least one member selected from the class consisting of polyvinyl pyrrolidone, polyvinyl acetate, acrylic polymers and combinations thereof, wherein the polyvinyl pyrrolidone is utilized in an amount of from about 1 to about 6 parts by weight per 100 parts of dry weight compounded latex solids, and the polyvinyl acetate and acrylic polymers are utilized, respectively, in an -amount of from about to about 50 parts by weight based on a corresponding 90 to 50 parts by weight of dry weight compounded latex solids, said rubber coating being dye-receptive following the drying and curing of said coating.

2. A rubber-backed fabric consisting of a fabric layer and a rubber coating on the back surface of said fabric layer, said rubber coating comprising a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber, said latex containing from about 1 to about 3 parts by Weight of polyvinyl pyrrolidone per 10() parts of dry weight compounded latex solids and thereby being rendered capable of accepting direct dyes when said fabric and coating are subjected to a dyeing operation.

3. A rubber-backed fabric consisting of a fabric layer and a rubber coating on the back surface of said fabric layer, said rubber coating comprising a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber, said latex containing from about 20 to about 40 parts by weight of polyvinyl acetate based on a corresponding 80 to 60 parts by weight of dry weight compounded latex solids and thereby being rendered capable of accepting acetate, acid and nylon dyes when said fabric and coating are subjected to a dyeing operation.

4. A rubber-backed fabric consisting of a fabric layer and a rubber coating on the back surface of said fabric layer, said rubber coating comprising a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber, said latex containing from about 20 to about 40 parts by weight of acrylic polymer based on a corresponding 80' to 60 parts by weight of dry weight compounded latex solids and thereby being rendered capable of accepting acetate, acid and nylon dyes when said fabric and coating are subjected to a dyeing operation.

5. In a method of preparing a substantially uniformly dye fabric and coating by applying a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber as a coating to the back surface of a fabric, drying and vulcanizing said latex thereon, and subjecting said fabric and coating to a subsequent dyeing treatment, the improvement comprising incorporating in said latex at least one member selected from the class consisting of polyvinyl pyrrolidone, polyvinyl acetate, acrylic polymers and combinations thereof, wherein the polyvinyl pyrrolidone is utilized in an amount of from about 1 to about 6 parts by weight per 100` parts of dry weight compounded latex solids, and the polyvinyl acetate and acrylic polymers are utilized, respectively, in an amount of from about 10 to `about 50 parts by weight based on a corresponding to 50 parts by weight of dry weight compounded lateX solids, whereby said latex is rendered capable of accepting dyestuifs.

6. In a method of preparing a substantially uniformly dye fabric and coating by applying a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber as a coating to the back surface of a fabric, drying and vulcanizing said latex thereon, said subjecting said fabric and coating to a subsequent dyeing treatment, the improvement comprising incorporating in said latex from about 1 to about 3 parts by Weight of polyvinyl pyyrolidone per parts of dry weight compounded latex solids, whereby the dried and vulcanized latex coating is rendered capable of accepting direct dyestuffs.

7. In a method of preparing a substantially uniformly dye fabric and coating by applying a compounded latex of la rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber as a coating to the back surface of a fabric, drying and vulcanizing said latex thereon, and subjecting said fabric and coating to a subsequent dyeing treatment, the improvement comprising incorporating in said latex from about 20 to about 40 parts by weight of polyvinyl acetate based on a corresponding 80 to 60 parts of dry weight compounded latex solids, whereby the dried and vulcanized latex coating is rendered capable of accepting acetate, acid and nylon dyestuffs.

8. In a method of preparing a substantially uniformly dyed fabric and coating by applying a compounded latex of a rubber selected from the group consisting of natural rubber, neoprene rubber and styrene-butadiene copolymer rubber as a coating to the back surface of a fabric, drying and vulcanizing said latex thereon, and subjecting said fabric and coating to a subsequent dyeing treatment, the improvement comprising incorporating in said latex from about 20 to about 40 parts by weight of acrylic polymer based on a corresponding 80 to 60 parts of dry weight compounded latex solids, whereby the dried and vulcanized latex coating is rendered capable of accepting acetate, acid and nylon dyestuifs.

References Cited in the le of this patent UNITED STATES PATENTS 1,989,246 Reed Jan. 29, 1935 2,078,881 Munzinger Apr. 27, 1937 2,194,579 Wedger Mar. 26, 1940 2,650,184 Biefeld Aug. 25, 1953 2,771,456 Konigsberg et al Nov. 20, 1956 2,790,783 Coover Apr. 30, 1957 2,882,253 Leierdink et al. Apr. 14, 1959 2,927,868 Revoir Mar. 8, 1960 2,932,550 Walmsley Apr. 12, 1960 UNITED STATES PATENT OFFICE CERTIFICATE 0F CORRECTION Patent Noo 3, 138,431 June 23, 1964 Jack W Swggett It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as Corrected below.

Column 5, line 53, column 6, lines 12 andg24, for "dye" each occurrence, read dyed column 6, line 16, for v'sa1d", second occurrence, read and Signed and sealed this 24th day of November 1964 (SEAL) Attest:

ERNEST W., SWIDER EDWARD J. BRENNER Altesting Officer Commissioner of Patents 

5. IN A METHOD OF PREPARING A SUBSTANTIALLY UNIFORMLY DYE FABRIC AND COATING BY APPLYING A COMPOUNDED LATEX OF A RUBBER SELECTED FROM THE GROUP CONSISTING OF NATURAL RUBBER, NEOPRENE RUBBER AND STYRENE-BUTADIENE COPOLYMER RUBBER AS A COATING TO THE BACK SURFACE OF A FABRIC, DRYING AND VULCANIZING SAID LATEX THEREON, AND SUBJECTING SAID FABRIC AND COATING TO A SUBSEQUENT DYEING TREATMENT, THE IMPROVEMENT COMPRISING INCORPORATING IN SAID LATEX AT LEAST ONE MEMBER SELECTED FROM THE CLASS CONSISTING OF POLYVINYL PYRROLIDONE, POLYVINYL ACETATE, ACRYLIC POLYMERS AND COMBINATIONS THEEOF, WHEREIN THE POLYVINYL PYRROLIDONE IS UTILIZED IN AN AMOUNT OF FROM ABOUT 1 TO ABOUT 6 PARTS BY WEIGHT PER 100 PARTS OF DRY WEIGHT COMPOUNDED LATEX SOLIDS, AND THE POLYVINYL ACETATE AND ACRYLIC POLYMERS ARE UTILIZED, RESPECTIVELY, IN AN AMOUNT OF FROM ABOUT 10 TO ABOUT 50 PARTS BY WEIGHT BASED ON A CORRESPONDING 90 TO 50 PARTS BY WEIGHT OF DRY WEIGHT COMPOUNDED LATEX SOLIDS, WHEREBY SAID LATEX IS RENDERED CAPABLE OF ACCEPTING DYESTUFFS. 